NHTSA lists 4 safety recalls and 1,408 owner complaints for the 2004 Ford Explorer. Most complaints involve power train (477) and structure (446). The EPA rates it 15–16 mpg combined.
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Complaints for each Explorer model year we’ve synced.
| Model year | NHTSA complaints |
|---|---|
| 1996 | 1,468 |
| 1997 | 1,789 |
| 1998 | 2,099 |
| 1999 | 1,465 |
| 2000 | 1,078 |
| 2001 | 730 |
| 2002 | 3,613 |
| 2003 | 1,313 |
| 2004 | 1,408 |
| 2005 | 568 |
| 2006 | 635 |
| 2007 | 208 |
| 2008 | 148 |
| 2009 | 33 |
| 2010 | 115 |
| 2011 | 1,197 |
| 2012 | 830 |
| 2013 | 2,237 |
| 2014 | 1,684 |
| 2015 | 1,814 |
| 2016 | 2,464 |
| 2017 | 1,713 |
| 2018 | 733 |
| 2019 | 302 |
| 2020 | 1,247 |
| 2021 | 452 |
| 2022 | 271 |
| 2023 | 113 |
| 2024 | 21 |
| 2025 | 107 |
| 2026 | 44 |
“MY 2004 FORD EXPLORER HAS RECENTLY AND QUICKLY BEGAN SHIFTING VERY BADLY. I ALWAYS COME TO A COMPLETE STOP AND SHIFT INTO NEUTRAL BEFORE SHIFTING INTO REVERSE OR DRIVE BECAUSE WHEN SHIFTING INTO REVERSE FROM P OR D, IT ALWAYS TAKES A WHILE, THEN CLUNKS AGGRESSIVELY INTO PLACE. WHILE DRIVING SOMETIMES DOWNSHIFTING WILL ALSO CLUNK INTO PLACE. THIS ISSUE HAS BEEN REPORTED BY COUNTLESS OTHER DRIVERS AND HAS CAUSED MANY POTENTIALLY DANGEROUS SITUATIONS. FROM ACCELERATING SLOWLY THEN BANGING GEARS AND TAKING OFF, TO STUTTERING WHILE TRYING TO ACCELERATE, OR EVEN SWITCHING INTO REVERSE WHILE PARKING, AND HAVING THE CAR TRY TO JUMP BACK A FEW INCHES IS ONLY A FEW ISSUES THIS PROBLEM HAS CAUSED MYSELF AND COUNTLESS OTHERS. PEOPLE ARE REPLACING TRANSMISSIONS LEFT AND RIGHT TO NO AVAIL, ONLY A FEW 10 THOUSAND MILES AFTER INSTALLING NEW TRANSMISSIONS, THEIR CAR STARTS TO EXPERIENCE THE SAME ISSUES AS BEFORE. AT LOW SPEEDS AND IN PARKING LOTS THIS BECOMES A GAME OF LUCK AS YOU ACCELERATE MORE THAN NECESSARY TO TRY TO GET GOING, THEN STOPPING AND WAITING A FEW SECONDS WHILE YOU SHIFT TO NEUTRAL BEFORE SHIFTING TO REVERSE AS FEAR OF IT BANGING INTO GEAR AS YOU TRY TO MANEUVER…”
“Back windows fell off track and windows fell down, cannot roll them up. AC and Heater broke and won't work at all. Fuel system is too lean. Transmission is going out Timing Chain and tensioners making loud knocking noise. Burning oil.”
“WHILE CLOSING THE REAR WINDOW GLASS HATCH THE DRIVER SIDE HINGE BROKE ALLOWING THE WINDOW TO FALL OUT ON THAT SIDE. THE REAR GLASS HATCH WINDOW IS HEAVY AND COULD HAVE EASILY BROKEN THE HINGE SIDE ALLOWING THE GLASS TO FALL OFF THE VEHICLE. A PREVIOUS FORD RECALL ON THE VERY SAME COMPONENT COVERED VEHICLES UP TO 2003. THE EXACT SAME PROBLEM IS OCCURRING TO THIS 2004 VEHICLE. CONTACTED FORD AND THEY ARE NOT WILLING TO HELP OWNERS OUT. HAD THE VEHICLE BEEN TRAVELING AT HIGHWAY SPEEDS AND THE HINGE LET GO, THERE WOULD BE A VERY HIGH PROBABILITY OF PROPERTY DAMAGE AND A VERY HIGH PROBABILITY OF PERSONAL INJURY TO OTHERS ON THE ROAD. *TR”
Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.
| Version | City | Hwy | Comb. | Fuel / yr | CO₂ g/mi |
|---|---|---|---|---|---|
| Explorer 2WD Auto 5-spd, 6 cyl, 4.0 L · Rear-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 2WD FFV Auto 5-spd, 6 cyl, 4.0 L · Rear-Wheel Drive | 14 | 20 | 16 | $3,900 | 555 |
| Explorer 4WD Auto 5-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 4WD FFV Auto 5-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 2WD Auto 5-spd, 8 cyl, 4.6 L · Rear-Wheel Drive | 13 | 18 | 15 | $4,150 | 592 |
| Explorer 4WD Auto 5-spd, 8 cyl, 4.6 L · 4-Wheel or All-Wheel Drive | 13 | 18 | 15 | $4,150 | 592 |
| Item | Miles | Time | Note |
|---|---|---|---|
| Engine oil & filter | 5,000–10,000 mi | 6–12 months | Follow the oil-life monitor if fitted |
| Tire rotation | 5,000–7,500 mi | Every oil change | Check pressure monthly |
| Engine air filter | 15,000–30,000 mi | 1–2 years | Sooner in dusty areas |
| Cabin air filter | 15,000–25,000 mi | 1–2 years | |
| Brake fluid | — | 2–3 years | Absorbs moisture over time |
| Coolant | 60,000–100,000 mi | 5–10 years | Long-life coolants last longer |
| Spark plugs | 60,000–100,000 mi | — | Iridium/platinum plugs at the long end |
| 12V battery | — | 3–5 years | Heat shortens battery life |
4 safety recalls as of Nov 7, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.
Owners filed 1,408 complaints with NHTSA. The most-cited components are power train (477), structure (446), visibility (101). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.
The EPA rates the 2004 Ford Explorer at 15–16 mpg combined, depending on engine and drivetrain (6 versions rated).